Resist composition and patterning process

ABSTRACT

A resist composition contains a polymer-bound acid generator, specifically a polymer comprising recurring units derived from a sulfonium or iodonium salt having a polymerizable unsaturated bond and containing iodine in the linker between the polymerizable unsaturated bond and a fluorosulfonic acid. The resist composition offers a high sensitivity and improved CDU independent of whether it is of positive or negative tone.

CROSS-REFERENCE TO RELATED APPLICATION

This non-provisional application claims priority under 35 U.S.C. § 119(a) on Patent Application No. 2017-100594 filed in Japan on May 22, 2017, the entire contents of which are hereby incorporated by reference.

TECHNICAL FIELD

This invention relates to a resist composition and a patterning process using the same.

BACKGROUND ART

To meet the demand for higher integration density and operating speed of LSIs, the effort to reduce the pattern rule is in rapid progress. The wide-spreading flash memory market and the demand for increased storage capacities drive forward the miniaturization technology. As the advanced miniaturization technology, manufacturing of microelectronic devices at the 65-nm node by the ArF lithography has been implemented in a mass scale. Manufacturing of 45-nm node devices by the next generation ArF immersion lithography is approaching to the verge of high-volume application. The candidates for the next generation 32-nm node include ultra-high NA lens immersion lithography using a liquid having a higher refractive index than water in combination with a high refractive index lens and a high refractive index resist film, EUV lithography of wavelength 13.5 nm, and double patterning version of the ArF lithography, on which active research efforts have been made.

As the pattern feature size is reduced, approaching to the diffraction limit of light, light contrast lowers. In the case of positive resist film, a lowering of light contrast leads to reductions of resolution and focus margin of hole and trench patterns.

As the pattern feature size is reduced, the edge roughness (LWR) of line patterns and the critical dimension uniformity (CDU) of hole patterns are regarded significant. It is pointed out that these factors are affected by the segregation or agglomeration of a base polymer and acid generator and the diffusion of generated acid. There is a tendency that as the resist film becomes thinner, LWR becomes greater. A film thickness reduction to comply with the progress of size reduction causes a degradation of LWR, which becomes a serious problem.

The EUV lithography resist must meet high sensitivity, high resolution and low LWR at the same time. As the acid diffusion distance is reduced, LWR is reduced, but sensitivity becomes lower. For example, as the PEB temperature is lowered, the outcome is a reduced LWR, but a lower sensitivity. As the amount of quencher added is increased, the outcome is a reduced LWR, but a lower sensitivity. It is necessary to overcome the tradeoff relation between sensitivity and LWR

Patent Document 1 discloses a resist compound comprising recurring units derived from an onium salt of a polymerizable unsaturated bond-containing sulfonic acid. The so-called polymer-bound acid generator is capable of generating a polymer type sulfonic acid upon exposure and characterized by a very short distance of acid diffusion. Sensitivity may be enhanced by increasing a proportion of the acid generator. In the case of addition type acid generators, as the amount of acid generator added is increased, a higher sensitivity is achievable, but the acid diffusion distance is also increased. Since the acid diffusion is non-uniform, increased acid diffusion leads to degraded LWR and CDU. With respect to a balance of sensitivity, LWR and CDU, the polymer-bound acid generator has a high capability.

CITATION LIST

Patent Document 1: JP 4425776

DISCLOSURE OF INVENTION

In the field of acid-catalyzed chemically amplified resist materials, it is desired to have a resist material having a higher sensitivity, improved LWR of line patterns, and improved CDU of hole patterns.

An object of the invention is to provide a resist composition which exhibits a high sensitivity and a reduced LWR or improved CDU, independent of whether it is of positive tone or negative tone; and a pattern forming process using the same.

The inventors have found that using a polymer comprising recurring units derived from a sulfonium or iodonium salt having a polymerizable unsaturated bond and containing a iodine atom in the linker between the polymerizable unsaturated bond and a fluorosulfonic acid, as the polymer-bound acid generator, a resist material having a high sensitivity, reduced LWR, improved CDU, high contrast, improved resolution, and wide process margin is obtainable.

In one aspect, the invention provides a resist composition comprising a polymer comprising recurring units having the formula (a1) or (a2).

Herein R^(A) is hydrogen or methyl; X¹ is a single bond or ester group; X² is a C₁-C₁₂ straight, branched or cyclic alkylene group or C₆-C₁₀ arylene group, any methylene moiety in the alkylene group may be substituted by an ether moiety, ester moiety or lactone ring-containing moiety, at least one hydrogen in the group X² is substituted by iodine; X³ is a single bond, ether group, ester group or C₁-C₁₂ straight, branched or cyclic alkylene group, any methylene moiety in the alkylene group may be substituted by an ether or ester moiety; Rf¹ to Rf⁴ are each independently hydrogen, fluorine or trifluoromethyl, at least one of Rf¹ to Rf⁴ is fluorine or trifluoromethyl, Rf¹ and Rf² may bond together to form a carbonyl group; R¹ to Rf⁴ are each independently a C₁-C₁₂ straight, branched or cyclic alkyl group, C₂-C₁₂ straight, branched or cyclic alkenyl group, C₂-C₁₂ straight, branched or cyclic alkynyl group, C₆-C₂₀ aryl group, C₁-C₂ aralkyl group, or C₇-C₁₂ aryloxyalkyl group, in which at least one hydrogen may be substituted by hydroxyl, carboxyl, halogen, oxo, cyano, amide, nitro, sultone, sulfone or sulfonium salt-containing moiety, and in which any methylene moiety may be substituted by an ether, ester, carbonyl, carbonate or sulfonate moiety, and R¹ and R² may bond together to form a ring with the sulfur atom to which they are attached.

Preferably the recurring units having formulae (a1) and (a2) are represented by the formulae (a1-1) and (a2-1), respectively.

Herein R^(A), R¹ to R⁵, Rf⁴ to Rf⁴, and X¹ are as defined above; R⁶ is a C₁-C₄ straight, branched or cyclic alkyl group, halogen atom exclusive of iodine, hydroxyl group. C₁-C₄ straight, branched or cyclic alkoxy group, or C₂-C₅ straight, branched or cyclic alkoxycarbonyl group, m is an integer of 1 to 4, and n is an integer of 0 to 3.

The resist composition may further comprise an organic solvent.

In a preferred embodiment, the polymer further comprises recurring units having to the formula (b1) or (b2).

Herein R^(A) is independently hydrogen or methyl; Y¹ is a single bond, phenylene group, naphthylene group, or a C₁-C₁₂ linking group containing an ester moiety and/or lactone ring; Y² is a single bond or ester group; R¹¹ and R¹² are each independently an acid labile group; R¹³ is halogen, trifluoromethyl, cyano, C₁-C₆ straight, branched or cyclic alkyl or alkoxy group, or C₂-C₇ straight, branched or cyclic acyl, acyloxy or alkoxycarbonyl group; R¹⁴ is a single bond or C₁-C₆ straight or branched alkylene group in which at least one carbon atom may be substituted by an ether or ester moiety, p is 1 or 2, and q is an integer of 0 to 4.

The resist composition may further comprise a dissolution inhibitor, the resist composition being a chemically amplified positive tone resist composition.

In one embodiment, the polymer is free of an acid labile group. The resist composition may further comprise a crosslinker, the resist composition being a chemically amplified negative tone resist composition.

The resist composition may further comprise a surfactant.

In another aspect, the invention provides a process for forming a pattern comprising the steps of applying the resist composition defined above onto a substrate, baking to form a resist film, exposing the resist film to high-energy radiation, and developing the exposed film in a developer.

In a preferred embodiment, the high-energy radiation is ArF excimer laser radiation of wavelength 193 nm, KrF excimer laser radiation of wavelength 248 nm, EB or EUV of wavelength 3 to 15 nm.

Advantageous Effects of Invention

A resist material containing a polymer comprising recurring units derived from a sulfonium or iodonium salt having a polymerizable unsaturated bond and containing iodine in the linker between the polymerizable unsaturated bond and a fluorosulfonic acid has the advantage of reduced acid diffusion because of the high atomic weight of iodine. This prevents resolution from declining due to blur by acid diffusion and enables to reduce LWR and improve CDU. Since iodine is highly absorptive to EUV of wavelength 13.5 nm, it generates secondary electrons during exposure, contributing to a higher sensitivity. Thus a resist material having a high sensitivity, low LWR and improved CDU may be designed.

DESCRIPTION OF EMBODIMENTS

As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. The notation (C_(n)-C_(m)) means a group containing from n to m carbon atoms per group. As used herein, the term “iodized” or “fluorinated” indicates that a compound contains iodine or fluorine. Me stands for methyl and Ac for acetyl.

The abbreviations and acronyms have the following meaning.

EB: electron beam

EUV: extreme ultraviolet

Mw: weight average molecular weight

Mn: number average molecular weight

Mw/Mn: molecular weight distribution or dispersity

GPC: gel permeation chromatography

PEB: post-exposure bake

PAG: photoacid generator

LWR: line width roughness

CDU: critical dimension uniformity

Resist Composition

The resist composition of the invention is defined as comprising a polymer-bound acid generator, specifically a polymer comprising recurring units derived from a sulfonium or iodonium salt having a polymerizable unsaturated bond and containing a iodine atom in the linker between the polymerizable unsaturated bond and a fluorosulfonic acid. In the resist composition, another acid generator capable of generating a sulfonic acid (different from the fluorosulfonic acid), imide acid or methide acid may be separately added.

When a resist composition containing the polymer-bound acid generator in admixture with a sulfonium salt capable of generating weaker acid such as sulfonic acid or carboxylic acid is exposed to radiation, a fluorosulfonic acid polymer containing iodine in the linker and weaker sulfonic acid or carboxylic acid generate. Since the acid generator is not entirely decomposed, the undecomposed sulfonium salt is present nearby. When the polymeric fluorosulfonic acid containing iodine in the linker co-exists with the sulfonium salt of weaker sulfonic acid or carboxylic acid, an ion exchange takes place between the polymeric fluorosulfonic acid containing iodine in the linker and the sulfonium salt of weaker sulfonic acid or carboxylic acid, whereby a sulfonium or iodonium salt of polymeric fluorosulfonic acid containing iodine in the linker is created and the weaker sulfonic acid or carboxylic acid is released. This is because the salt of polymeric fluorosulfonic acid containing iodine in the linker having a high acid strength is more stable. In contrast, when a sulfonium salt of polymeric fluorosulfonic acid containing iodine in the linker co-exists with a weaker sulfonic acid or carboxylic acid, no ion exchange takes place. The ion exchange reaction according to the acid strength series occurs not only with sulfonium salts, but also similarly with iodonium salts. When combined with an acid generator for fluorosulfonic acid, a sulfonium or iodonium salt of weak acid functions as a quencher. Since iodine is highly absorptive to EUV of wavelength 13.5 nm, it generates secondary electrons upon EUV exposure. The energy of secondary electrons is transferred to the acid generator to promote its decomposition, contributing to a higher sensitivity. The polymer-bound acid generator is effective for achieving low acid diffusion and high sensitivity.

For the LWR improving purpose, it is effective to prevent a polymer and/or acid generator from agglomeration. Effective means for preventing agglomeration of a polymer is by reducing the difference between hydrophobic and hydrophilic properties or by lowering the glass transition temperature (Tg) or molecular weight thereof. Specifically, it is effective to reduce the polarity difference between a hydrophobic acid labile group and a hydrophilic adhesive group or to lower the Tg by using a compact adhesive group like monocyclic lactone. One effective means for preventing agglomeration of an acid generator is by introducing a substituent into the triphenylsulfonium cation. In particular, with respect to a methacrylate polymer containing an alicyclic protective group and a lactone adhesive group for ArF lithography, a triphenylsulfonium composed solely of aromatic groups has a heterogeneous structure and low compatibility. As the substituent to be introduced into triphenylsulfonium, an alicyclic group or lactone similar to those used in the base polymer is regarded adequate. When lactone is introduced in a sulfonium salt which is hydrophilic, the resulting sulfonium salt becomes too hydrophilic and thus less compatible with a polymer, with a likelihood that the sulfonium salt will agglomerate. When a hydrophobic alkyl group is introduced, the sulfonium salt may be uniformly dispersed within the resist film. WO 2011/048919 discloses the technique for improving LWR by introducing an alkyl group into a sulfonium salt capable of generating an α-fluorinated sulfone imide acid.

The polymer-bound acid generator used herein is less diffusive because the anion moiety is bound to the polymer backbone and iodine having a large atomic weight is introduced in the anion moiety, and higher in acid generation efficiency because iodine is highly absorptive. Since the acid generator is mixed with monomers prior to polymerization, the acid generator is uniformly dispersed in the polymer. These lead to improvements in LWR and CDU.

The polymer-bound acid generator exerts a LWR or CDU improving effect, which may stand good either in positive and negative tone pattern formation by alkaline development or in negative tone pattern formation by organic solvent development.

Polymer-Bound Acid Generator

The polymer-bound acid generator used herein is a polymer comprising recurring units derived from a sulfonium or iodonium salt having a polymerizable unsaturated bond and containing a iodine atom in the linker between the polymerizable unsaturated bond and a fluorosulfonic acid and specifically, a polymer comprising recurring units having the formula (a1) or (a2). It is noted that recurring units having the formula (a1) or (a2) are simply referred to as recurring units (a1) or (a2), hereinafter.

Herein R^(A) is hydrogen or methyl. X¹ is a single bond or ester group. X² is a C₁-C₁₂ straight, branched or cyclic alkylene group or C₆-C₁₀ arylene group, any methylene moiety in the alkylene group may be substituted by an ether moiety, ester moiety or lactone ring-containing moiety, and at least one hydrogen in the group X² is substituted by iodine. X³ is a single bond, ether group, ester group or C₁-C₁₂ straight, branched or cyclic alkylene group, any methylene moiety in the alkylene group may be substituted by an ether or ester moiety. Rf¹ to Rf¹ are each independently hydrogen, fluorine or trifluoromethyl at least one of Rf¹ to Rf⁴ is fluorine or trifluoromethyl, and Rf¹ and Rf² may bond together to form a carbonyl group. R¹ to R⁵ are each independently a C₁-C₁₂ straight, branched or cyclic alkyl group, C₂-C₁₂ straight, branched or cyclic alkenyl group, C₂-C₁₂ straight, branched or cyclic alkynyl group, C₆-C₂₀ aryl group, C₇-C₁₂ aralkyl group, or C₇-C₁₂ aryloxyalkyl group, in which at least one hydrogen (one or more or even all hydrogen atoms) may be substituted by hydroxyl, carboxyl, halogen, oxo, cyano, amide, nitro, sultone, sulfone or sulfonium salt-containing moiety, and in which any methylene moiety may be substituted by an ether, ester, carbonyl, carbonate or sulfonate moiety. Also, R¹ and R² may bond together to form a ring with the sulfur atom to which they are attached.

Preferably, the recurring units (a1) and (a2) are represented by the formulae (a1-1) and (a2-1), respectively.

Herein R^(A), R¹ to R⁵, Rf¹ to Rf⁴, and X¹ are as defined above. R⁶ is a C₁-C₄ straight, branched or cyclic alkyl group, halogen atom exclusive of iodine, hydroxyl group, C₁-C₄ straight, branched or cyclic alkoxy group, or C₂-C₅ straight, branched or cyclic alkoxycarbonyl group, m is an integer of 1 to 4, and n is an integer of 0 to 3.

Examples of the anion moiety in the monomer from which recurring units (a1) or (a2) are derived are given below, but not limited thereto.

Examples of the cation moiety in recurring unit (a1) are given below, but not limited thereto.

Examples of the cation moiety in recurring unit (a2) are given below, but not limited thereto.

The monomer from which recurring units (a1) or (a2) are derived may be synthesized, for example, by the same method as the synthesis of a sulfonium salt having a polymerizable anion described in U.S. Pat. No. 8,057,985 (JP 5201363).

The polymer-bound acid generator can also function as a base polymer. In this regard, where the resist composition is a chemically amplified positive tone resist composition, the polymer-bound acid generator is a polymer further comprising recurring units containing an acid labile group, preferably recurring units having the formula (b1) or recurring units having the formula (b2). These units are simply referred to as recurring units (b1) and (b2).

Herein R^(A) is each independently hydrogen or methyl. Y¹ is a single bond, phenylene group or naphthylene group, or C₁-C₁₂ linking group containing ester moiety and/or lactone ring. Y² is a single bond or ester group. R¹¹ and R¹² are each independently an acid labile group. R¹³ is halogen, trifluoromethyl, cyano, a C₁-C₆ straight, branched or cyclic alkyl or alkoxy group, or a C₂-C₇ straight, branched or cyclic acyl, acyloxy or alkoxycarbonyl group. R¹⁴ is a single bond or C₁-C₆ straight or branched alkylene group in which one or more carbon atoms may be substituted by an ether or ester moiety, p is 1 or 2, and q is an integer of 0 to 4.

Examples of the recurring units (b1) are shown below, but not limited thereto. R^(A) and R¹¹ are as defined above.

Examples of the recurring units (b2) are shown below, but not limited thereto. R^(A) and R¹² are as defined above.

The acid labile groups represented by R¹¹ and R¹² in formulae (b1) and (b2) may be selected from a variety of such groups, for example, those groups described in JP-A 2013-080033 (U.S. Pat. No. 8,574,817) and JP-A 2013-083821 (U.S. Pat. No. 8,846,303).

Typical of the acid labile group are groups of the following formulae (AL-1) to (AL-3).

In formulae (AL-1) and (AL-2), R²¹ and R²⁴ are each independently a monovalent hydrocarbon group of 1 to 40 carbon atoms, preferably 1 to 20 carbon atoms, typically straight, branched or cyclic alkyl, which may contain a heteroatom such as oxygen, sulfur, nitrogen or fluorine. R²² and R²³ are each independently hydrogen or a monovalent hydrocarbon group of 1 to 20 carbon atoms, typically straight, branched or cyclic alkyl, which may contain a heteroatom such as oxygen, sulfur, nitrogen or fluorine. Any two of R²², R²³ and R²⁴ may bond together to form a ring, typically alicyclic, with the carbon atom or carbon and oxygen atoms to which they are attached, the ring containing 3 to 20 carbon atoms, preferably 4 to 16 carbon atoms. The subscript k is an integer of 0 to 10, especially 1 to 5.

In formula (AL-3), R²⁵, R²⁶ and R²⁷ are each independently a monovalent hydrocarbon group of 1 to 20 carbon atoms, typically straight, branched or cyclic alkyl, which may contain a heteroatom such as oxygen, sulfur, nitrogen or fluorine. Any two of R²⁵, R²⁶ and R²⁷ may bond together to form a ring, typically alicyclic, with the carbon atom to which they are attached, the ring containing 3 to 20 carbon atoms, preferably 4 to 16 carbon atoms.

When the polymer-bound acid generator also functions as a base polymer, the polymer may further comprise recurring units (c) having a phenolic hydroxyl group as an adhesive group. Examples of suitable monomers from which recurring units (c) are derived are given below, but not limited thereto. Herein R^(A) is as defined above.

When the polymer-bound acid generator also functions as a base polymer, the polymer may further comprise recurring units (d) having another adhesive group selected from hydroxyl (other than the foregoing phenolic hydroxyl), carboxyl, lactone ring, ether, ester, carbonyl and cyano groups. Examples of suitable monomers from which recurring to units (d) are derived are given below, but not limited thereto. Herein R^(A) is as defined above.

In the case of a monomer having a hydroxyl group, the hydroxyl group may be replaced by an acetal group susceptible to deprotection with acid, typically ethoxyethoxy, prior to polymerization, and the polymerization be followed by deprotection with weak acid and water. Alternatively, the hydroxyl group may be replaced by an acetyl, formyl, pivaloyl or similar group prior to polymerization, and the polymerization be followed by alkaline hydrolysis.

When the polymer-bound acid generator also functions as a base polymer, the polymer may further comprise recurring units (e) derived from indene, benzofuran, benzothiophene, acenaphthylene, chromone, coumarin, and norbornadiene, or derivatives thereof. Suitable monomers are exemplified below.

When the polymer-bound acid generator also functions as a base polymer, the polymer may further comprise recurring units (f) derived from indane, vinylpyridine or vinylcarbazole.

In a further embodiment, the polymer-bound acid generator may further comprise recurring units (g) derived from an onium salt having a polymerizable unsaturated bond other than the recurring units (a1) and (a2). Typical recurring units (g) are described, for example, in U.S. Pat. No. 9,810,983 (JP-A 2017-008181, paragraph [0060]).

The base polymer for formulating the positive resist composition comprises recurring units (a1) and/or (a2) and recurring units (b1) and/or (b2) having an acid labile group as essential components and additional recurring units (c), (d), (e), (f) and (g) as optional components. A fraction of units (a1), (a2), (b1), (b2), (c), (d), (e), (f), and (g) is: preferably 0≤a1<1.0, 0≤a2<1.0, 0<a1+a2<1.0, 0≤b1<1.0, 0≤b2<1.0, 0<b1+b2<1.0, 0≤c≤0.9, 0≤d≤0.9, 0≤e≤0.8, 0<f<0.8, and 0≤g≤0.4; more preferably 0≤a1≤0.7, 0≤a2≤0.7, 0.02≤a1+a2≤0.7, 0≤b1≤0.9, 0≤b2≤0.9, 0.1≤b1+b2≤0.9, 0≤c≤0.8, 0≤d≤0.8, 0≤e≤0.7, 0≤f≤0.7, and 0≤g≤0.3; and even more preferably 0≤a1≤0.5, 0≤a2≤0.5, 0.03≤a1+a2≤0.5, 0≤b1≤0.8, 0≤b2≤0.8, 0.1≤b1+b2<0.8, 0≤c≤0.7, 0≤d≤0.7, 0≤e≤0.6, 0≤f≤0.6, and 0≤g≤0.2. Notably, a1+a2+b1+b2+c+d+e+f+g=1.0.

For the base polymer for formulating the negative resist composition, an acid labile group is not necessarily essential. The base polymer comprises recurring units (a1) and/or (a2) as essential component, and additional recurring units (c), (d), (e), (f) and (g) as optional components. A fraction of these units is: preferably 0≤a1<1.0, 0≤a2<1.0, 0<a1+a2<1.0, 0≤c<1.0, 00≤d≤0.9, 0≤e≤0.8, 0≤f≤0.8, and 0≤g≤0.4; more preferably 0≤a1≤0.7, 0≤a2≤0.7, 0.02≤a1+a2≤0.7, 0.2≤c<1.0, 0≤d≤0.8, 0≤e≤0.7, 0≤f≤0.7, and 0<g≤0.3; and even more preferably 0≤a1≤0.5, 0≤a2≤0.5, 0.03≤a1+a2≤0.5, 0.3≤c<1.0, 0≤d≤0.75, 0≤e≤0.6, 0≤f≤0.6, and 0≤g≤0.2. Notably, a1+a2+c+d+e+f+g=1.0.

The polymer-bound acid generator may be synthesized by any desired methods, for example, by dissolving suitable monomers selected from the monomers corresponding to the foregoing recurring units in an organic solvent, adding a radical polymerization initiator thereto, and heating to conduct polymerization. Examples of the organic solvent which can be used for polymerization include toluene, benzene, tetrahydrofuran (THF), diethyl ether, and dioxane. Examples of the polymerization initiator used herein include 2,2′-azobisisobutyronitrile (AIBN), 2,2′-azobis(2,4-dimethylvaleronitrile), dimethyl 2,2-azobis(2-methylpropionate), benzoyl peroxide, and lauroyl peroxide. Preferably the system is heated at 50 to 80° C. for polymerization to take place. The reaction time is 2 to 100 hours, preferably 5 to 20 hours.

When hydroxystyrene or hydroxyvinylnaphthalene is copolymerized, an alternative method is possible. Specifically, acetoxystyrene or acetoxyvinylnaphthalene is used instead of hydroxystyrene or hydroxyvinylnaphthalene, and after polymerization, the acetoxy group is deprotected by alkaline hydrolysis, for thereby converting the relevant units to hydroxystyrene or hydroxyvinylnaphthalene units. For alkaline hydrolysis, a base such as aqueous ammonia or triethylamine may be used. Preferably the reaction temperature is −20° C. to 100° C., more preferably 0° C. to 60° C., and the reaction time is 0.2 to 100 hours, more preferably 0.5 to 20 hours.

The polymer-bound acid generator should preferably have a weight average molecular weight (Mw) in the range of 1,000 to 500,000, and more preferably 2,000 to 30,000, as measured by GPC versus polystyrene standards using THF solvent. A Mw in the range ensures that the resist composition is heat resistant.

If a base polymer has a wide molecular weight distribution or dispersity (Mw/Mn), which indicates the presence of lower and higher molecular weight polymer fractions, there is a possibility that foreign matter is left on the pattern or the pattern profile is degraded. The influences of molecular weight and dispersity become stronger as the pattern rule becomes finer. Therefore, the polymer-bound acid generator should preferably have a narrow dispersity (Mw/Mn) of 1.0 to 2.0, especially 1.0 to 1.5, in order to provide a resist composition suitable for micropatterning to a small feature size.

It is understood that a blend of two or more polymer-bound acid generators which differ in compositional ratio. Mw or Mw/Mn is acceptable.

Other Components

With the polymer-bound acid generator defined above, other components such as another acid generator, an organic solvent, surfactant, dissolution inhibitor, crosslinker, and quencher may be blended in any desired combination to formulate a chemically amplified positive or negative resist composition. This positive or negative resist composition has a very high sensitivity in that the dissolution rate in developer of the base polymer in exposed areas is accelerated by catalytic reaction. In addition, the resist film has a high dissolution contrast, resolution, exposure latitude, and process adaptability, and provides a good pattern profile after exposure, and minimal proximity bias because of restrained acid diffusion. By virtue of these advantages, the composition is fully useful in commercial application and suited as a pattern-forming material for the fabrication of VLSIs. Particularly when a chemically amplified positive resist composition capable of utilizing acid catalyzed reaction is formulated, the composition has a higher sensitivity and is further improved in the properties described above.

The resist composition may contain an acid generator other than the polymer-bound acid generator as long as the benefits of the invention are not compromised. The other acid generator is typically a compound (PAG) capable of generating an acid upon exposure to actinic ray or radiation. Although the PAG used herein may be any compound capable of generating an acid upon exposure to high-energy radiation, those compounds capable of generating sulfonic acid, imide acid (imidic acid) or methide acid are preferred. Suitable PAGs include sulfonium salts, iodonium salts, sulfonyldiazomethane, N-sulfonyloxyimide, and oxime-O-sulfonate acid generators. Exemplary acid generators are described in U.S. Pat. No. 7,537,880 (JP-A 2008-111103, paragraphs [0122]-[0142]).

Also, a sulfonium salt having the formula (1-1) and a iodonium salt having the formula (1-2) are advantageously used as the other acid generator.

In formulae (1-1) and (1-2), R¹⁰¹, R¹⁰², R¹⁰³, R¹⁰⁴ and R¹⁰⁵ are each independently a C₅-C₂₀ straight, branched or cyclic monovalent hydrocarbon group which may contain a heteroatom, any two of R¹⁰¹, R¹⁰² and R¹⁰³ may bond together to form a ring with the sulfur atom to which they are attached.

The cation moiety in the sulfonium salt having formula (1-1) is as exemplified above for the cation moiety in recurring unit (a1). The cation moiety in the iodonium salt having formula (1-2) is as exemplified above for the cation moiety in recurring unit (a2).

In formulae (1-1) and (1-2), X⁻ is an anion selected from the formulae (1A) to (1D).

In formula (1A), R^(fa) is fluorine or a C₁-C₄₀ straight, branched or cyclic monovalent hydrocarbon group which may contain a heteroatom.

Of the anions of formula (1A), a structure having formula (1A′) is preferred.

In formula (1A′), R¹⁰⁶ is hydrogen or trifluoromethyl, preferably trifluoromethyl. R¹⁰⁷ is a C₁-C₃₈ straight, branched or cyclic monovalent hydrocarbon group which may contain a heteroatom. Suitable heteroatoms include oxygen, nitrogen, sulfur and halogen, with oxygen being preferred. Of the monovalent hydrocarbon groups, those of 6 to 30 carbon atoms are preferred because a high resolution is available in fine pattern formation. Suitable monovalent hydrocarbon groups include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, s-butyl, t-butyl, pentyl, neopentyl, cyclopentyl, hexyl, cyclohexyl, 3-cyclohexenyl, heptyl, 2-ethylhexyl, nonyl, undecyl, tridecyl, pentadecyl, heptadecyl, 1-adamantyl, 2-adamantyl, 1-adamantylmethyl, norbornyl, norbornylmethyl, tricyclodecanyl, tetracyclododecanyl, tetracyclododecanylmethyl, dicyclohexylmethyl, icosanyl, allyl, benzyl, diphenylmethyl, tetrahydrofuryl, methoxymethyl, ethoxymethyl, methylthiomethyl, acetamidomethyl, trifluoroethyl, (2-methoxyethoxy)methyl, acetoxymethyl, 2-carboxy-1-cyclohexyl, 2-oxopropyl, 4-oxo-1-adamantyl, and 3-oxocyclohexyl. Also included are the foregoing groups in which at least one hydrogen is replaced by a radical containing a heteroatom such as oxygen, sulfur, nitrogen or halogen, or in which at least one carbon atom is substituted by a radical containing a heteroatom such as oxygen, sulfur or nitrogen, so that the group may contain a hydroxyl, cyano, carbonyl, ether, ester, sulfonic acid ester, carbonate, lactone ring, sultone ring, carboxylic acid anhydride or haloalkyl radical.

With respect to the synthesis of the sulfonium salt having an anion of formula (1A′), reference is made to JP-A 2007-145797, JP-A 2008-106045, JP-A 2009-007327, and JP-A 2009-258695. Also useful are the sulfonium salts described in JP-A 2010-215608, JP-A 2012-041320, JP-A 2012-106986, and JP-A 2012-153644.

Examples of the anion having formula (1A) are shown below, but not limited thereto.

In formula (1B), R^(fb1) and R^(fb2) are each independently fluorine or a C₁-C₀₄ straight, branched or cyclic monovalent hydrocarbon group which may contain a heteroatom. Suitable monovalent hydrocarbon groups are as exemplified above for R¹⁰⁷. Preferably R^(fb1) and R^(fb2) each are fluorine or a straight C₁-C₄ fluorinated alkyl group. A pair of R^(fb1) and R^(fb2) may bond together to form a ring with the linkage (—CF₂—SO₂—N⁻—SO₂—CF₂—) to which they are attached, and preferably the pair is a fluorinated ethylene or fluorinated propylene group.

In formula (1C), R^(fc1), R^(fc2) and R^(fc3) are each independently fluorine or a C₁-C₄₀ straight, branched or cyclic monovalent hydrocarbon group which may contain a heteroatom. Suitable monovalent hydrocarbon groups are as exemplified above for R¹⁰⁷. Preferably R^(fc1), R^(fc2) and R^(fc3) each are fluorine or a straight C₁-C₄ fluorinated alkyl group. A pair of R^(fc1) and R^(fc2) may bond together to form a ring with the linkage (—CF₂—SO₂—C⁻—SO₂—CF₂—) to which they are attached, and preferably the pair is a fluorinated ethylene or fluorinated propylene group.

In formula (1D), R^(fd) is a C₁-C₄₀ straight, branched or cyclic monovalent hydrocarbon group which may contain a heteroatom. Suitable monovalent hydrocarbon groups are as exemplified above for R¹⁰⁷.

With respect to the synthesis of the sulfonium salt having an anion of formula (1D), reference is made to JP-A 2010-215608 and JP-A 2014-133723.

Examples of the anion having formula (1D) are shown below, but not limited thereto.

The compound having the anion of formula (1D) has a sufficient acid strength to cleave acid labile groups in the base polymer because it is free of fluorine at α-position of sulfo group, but has two trifluoromethyl groups at β-position. Thus the compound is a useful PAG.

A compound having the formula (2) is also a useful PAG.

In formula (2), R²⁰¹ and R²⁰² are each independently a C₁-C₃₀ straight, branched or cyclic monovalent hydrocarbon group which may contain a heteroatom. R²⁰³ is a C₁-C₃₀ straight, branched or cyclic divalent hydrocarbon group which may contain a heteroatom. Any two of R²⁰¹, R²⁰² and R²⁰³ may bond together to form a ring with the sulfur atom to which they are attached. L^(A) is a single bond, ether group or a C₁-C₂₀ straight, branched or cyclic divalent hydrocarbon group which may contain a heteroatom. X^(A), X^(B), X^(C) and X^(D) are each independently hydrogen, fluorine or trifluoromethyl, with the proviso that at least one of X^(A), X^(B), X^(C) and X^(D) is fluorine or trifluoromethyl, and k is an integer of 0 to 3.

Suitable monovalent hydrocarbon groups include methyl, ethyl, propyl, isopropyl, n-butyl, s-butyl, t-butyl, n-pentyl, t-pentyl, n-hexyl, n-octyl, n-nonyl, n-decyl, cyclopentyl, cyclohexyl, 2-ethylhexyl, cyclopentylmethyl, cyclopentylethyl, cyclopentylbutyl, cyclohexylmethyl, cyclohexylethyl, cyclohexylbutyl, norbornyl, oxanorbornyl, tricyclo[5.2.1.0^(2,6)]decanyl, adamantyl, phenyl, naphthyl and anthracenyl. Also included are the foregoing groups in which at least one hydrogen is replaced by a heteroatom such as oxygen, sulfur, nitrogen or halogen, or in which at least one carbon is replaced by a heteroatom such as oxygen, sulfur or nitrogen, so that the group may contain a hydroxyl, cyano, carbonyl, ether bond, ester bond, sulfonic acid ester bond, carbonate bond, lactone ring, sultone ring, carboxylic acid anhydride or haloalkyl radical.

Suitable divalent hydrocarbon groups include linear alkane diyl groups such as methylene, ethylene, propane-1,3-diyl, butane-1,4-diyl, pentane-1,5-diyl, hexane-1,6-diyl, heptane-1,7-diyl, octane-1,8-diyl, nonane-1,9-diyl, decane-1,10-diyl, undecane-1,11-diyl, dodecane-1,12-diyl, tridecane-1,13-diyl, tetradecane-1,14-diyl, pentadecane-1,15-diyl, hexadecane-1,16-diyl, heptadecane-1,17-diyl; saturated cyclic divalent hydrocarbon groups such as cyclopentanediyl, cyclohexanediyl, norbornanediyl, and adamantanediyl, and unsaturated cyclic divalent hydrocarbon groups such as phenylene and naphthylene. Also included are the foregoing groups in which at least one hydrogen atom is replaced by an alkyl group such as methyl, ethyl, propyl, n-butyl or t-butyl, or in which at least one hydrogen atom is replaced by a radical containing a heteroatom such as oxygen, sulfur, nitrogen or halogen, or in which at least one carbon atom is replaced by a radical containing a heteroatom such as oxygen, sulfur or nitrogen, so that the group may contain a hydroxyl, cyano, carbonyl, ether, ester, sulfonic acid ester, carbonate, lactone ring, sultone ring, carboxylic acid anhydride or haloalkyl radical. Suitable heteroatoms include oxygen, nitrogen, sulfur and halogen, with oxygen being preferred.

Of the PAGs having formula (2), those having formula (2′) are preferred.

In formula (2′), L^(A) is as defined above. R is hydrogen or trifluoromethyl, preferably trifluoromethyl. R³⁰¹, R³⁰² and R³⁰³ are each independently hydrogen or a C₁-C₂₀ straight, branched or cyclic monovalent hydrocarbon group which may contain a heteroatom. Suitable monovalent hydrocarbon groups are as exemplified above for R¹⁰⁷. The subscripts x and y each are an integer of 0 to 5, and z is an integer of 0 to 4.

Examples of the PAG having formula (2) are shown below, but not limited thereto. Herein R is as defined above.

Of the foregoing PAGs, those compounds having an anion of formula (1A′) or (1D) are especially preferred because of reduced acid diffusion and high solubility in resist solvent, and those compounds having an anion of formula (2′) are especially preferred because of minimized acid diffusion.

Also sulfonium and iodonium salts of iodized benzoyloxy-containing fluorinated sulfonic acid having the formulae (3-1) and (3-2) are useful as the other acid generator.

In formulae (3-1) and (3-2), R³¹ is hydrogen, hydroxyl, carboxyl, nitro, cyano, fluorine, chlorine, bromine, amino group, or a straight, branched or cyclic, C₁-C₂₀ alkyl, C₁-C₂₀ alkoxy. C₂-C₂₀ alkoxycarbonyl, C₂-C₂ acyloxy or C₁-C₄ alkylsulfonyloxy group, which may contain fluorine, chlorine, bromine, hydroxy, amino or alkoxy moiety, or —NR³⁷—C(O)—R³⁸ or —NR³⁷—C(O)—O—R³⁸ wherein R³⁷ is hydrogen, or a straight, branched or cyclic C₁-C₆ alkyl group which may contain halogen, hydroxy, alkoxy, acyl or acyloxy moiety, R³⁸ is a straight, branched or cyclic, C₁-C₁₆ alkyl or C₂-C₁₆ alkenyl group, or C₆-C₁₂ aryl group, which may contain halogen, hydroxy, alkoxy, acyl or acyloxy moiety. X¹¹ is a single bond or a C₁-C₂ divalent linking group when r=1, or a C₁-C₂₀ tri- or tetravalent linking group when r=2 or 3, the linking group optionally containing an oxygen, sulfur or nitrogen atom. Rf¹⁴ to Rf¹⁴ are each independently hydrogen, fluorine or trifluoromethyl, at least one of Rf¹¹ to R¹⁴ being fluorine or trifluoromethyl, or Rf¹¹ and Rf¹², taken together, may form a carbonyl group. R³², R³³, R³⁴, R³⁵ and R³⁶ are each independently a C₁-C₁₂ straight, branched or cyclic alkyl group, C₂-C₁₂ straight, branched or cyclic alkenyl group, C₁-C₂ straight, branched or cyclic alkynyl group, C₁-C₂₀ aryl group, C₁-C₁₂ aralkyl group or C₁-C₁₂ aryloxyalkyl group, in which at least one hydrogen (one or more or even all hydrogen atoms) may be substituted by a hydroxy, carboxy, halogen, cyano, oxo, amide, nitro, sultone, sulfone or sulfonium salt-containing moiety, or in which an ether, ester, carbonyl, carbonate or sulfonic acid ester moiety may intervene between carbon atoms, or R³² and R³³ may bond together to form a ring with the sulfur atom to which they are attached, r is an integer of 1 to 3, s is an integer of 1 to 5, and t is an integer of 0 to 3.

Further, sulfonium and iodonium salts of iodized phenoxy or iodized to phenylalkoxy-containing fluorinated sulfonic acid having the formulae (3-3) and (3-4) are useful as the other acid generator.

In formulae (3-3) and (3-4). R⁴¹ is each independently a hydroxyl. C₁-C₂₀ straight, branched or cyclic alkyl or alkoxy group. C₁-C₂₀ straight, branched or cyclic acyl or acyloxy group, fluorine, chlorine, bromine, amino, or alkoxycarbonyl-substituted amino group. R⁴² is each independently a single bond or C₁-C₄ alkylene group. R⁴³ is a single bond or C₁-C₂₀ divalent linking group when u=1, or a C₁-C₂₀ tri- or tetravalent linking group when u=2 or 3, the linking group optionally containing an oxygen, sulfur or nitrogen atom. Rf²¹ to Rf²⁴ are each independently hydrogen, fluorine or trifluoromethyl, at least one of Rf²¹ to Rf²⁴ being fluorine or trifluoromethyl, or Rf²¹ and Rf²², taken together, may form a carbonyl group. R⁴⁴, R⁴⁵, R⁴⁶, R⁴⁷ and R⁴⁸ are each independently a C₁-C₁₂ straight, branched or cyclic alkyl group, C₂-C₁₂ straight, branched or cyclic alkenyl group, C₆-C₂₀ aryl group or C₁-C₁₂ aralkyl or aryloxyalkyl group, in which at least one hydrogen (one or more or even all hydrogen atoms) may be substituted by a hydroxyl, carboxyl, halogen, cyano, oxo, amide, nitro, sultone, sulfone, or sulfonium salt-containing moiety, or in which an ether, ester, carbonyl, carbonate or sulfonic acid ester moiety may intervene in a carbon-carbon bond, or R⁴⁴ and R⁴⁵ may bond together to form a ring with the sulfur atom to which they are attached, u is an integer of 1 to 3, v is an integer of 1 to 5, and w is an integer of 0 to 3.

The cation moiety in the sulfonium salt having formula (3-1) or (3-3) is as exemplified above for the cation moiety in recurring unit (a1). The cation moiety in the iodonium salt having formula (3-2) or (3-4) is as exemplified above for the cation moiety in recurring unit (a2).

Examples of the anion moiety in the onion salts having formulae (3-1) to (3-4) are given below, but not limited thereto.

In the resist composition, the other acid generator is preferably used in an amount of 0 to 200 parts, more preferably 0.1 to 100 parts by weight per 100 parts by weight of the base polymer.

In the case of positive resist compositions, inclusion of a dissolution inhibitor may lead to an increased difference in dissolution rate between exposed and unexposed areas and a further improvement in resolution. In the case of negative resist compositions, a negative pattern may be formed by adding a crosslinker to reduce the dissolution rate of exposed area.

Examples of the organic solvent used herein are described in JP-A 2008-111103, paragraphs [0144]-[0145] (U.S. Pat. No. 7,537,880). Exemplary solvents include ketones such as cyclohexanone, cyclopentanone and methyl-2-n-pentyl ketone; alcohols such as 3-methoxybutanol, 3-methyl-3-methoxybutanol, 1-methoxy-2-propanol, and 1-ethoxy-2-propanol; ethers such as propylene glycol monomethyl ether, ethylene glycol monomethyl ether, propylene glycol monoethyl ether, ethylene glycol monoethyl ether, propylene glycol dimethyl ether, and diethylene glycol dimethyl ether; esters such as propylene glycol monomethyl ether acetate (PGMEA), propylene glycol monoethyl ether acetate, ethyl lactate, ethyl pyruvate, butyl acetate, methyl 3-methoxypropionate, ethyl 3-ethoxypropionate, t-butyl acetate, t-butyl propionate, and propylene glycol mono-t-butyl ether acetate; and lactones such as γ-butyrolactone, which may be used alone or in admixture.

The organic solvent is preferably added in an amount of 100 to 10.000 parts, and more preferably 200 to 8,000 parts by weight per 100 parts by weight of the base polymer.

Exemplary surfactants are described in JP-A 2008-111103, paragraphs [0165]-[0166]. Inclusion of a surfactant may improve or control the coating characteristics of the resist composition. The surfactant is preferably added in an amount of 0.0001 to 10 parts by weight per 100 parts by weight of the base polymer.

The dissolution inhibitor which can be used herein is a compound having at least two phenolic hydroxyl groups on the molecule, in which an average of from 0 to 100 mol % of all the hydrogen atoms on the phenolic hydroxyl groups are replaced by acid labile groups or a compound having at least one carboxyl group on the molecule, in which an average of 50 to 100 mol % of all the hydrogen atoms on the carboxyl groups are replaced by acid labile groups, both the compounds having a molecular weight of 100 to 1,000, and preferably 150 to 800. Typical are bisphenol A, trisphenol, phenolphthalein, cresol novolac, naphthalenecarboxylic acid, adamantanecarboxylic acid, and cholic acid derivatives in which the hydrogen atom on the hydroxyl or carboxyl group is replaced by an acid labile group, as described in U.S. Pat. No. 7,771,914 (JP-A 2008-122932, paragraphs [0155]-[0178]).

In the positive resist composition, the dissolution inhibitor is preferably added in an amount of 0 to 50 parts, more preferably 5 to 40 parts by weight per 100 parts by weight of the base polymer.

Suitable crosslinkers which can be used herein include epoxy compounds, melamine compounds, guanamine compounds, glycoluril compounds and urea compounds having substituted thereon at least one group selected from among methylol alkoxymethyl and acyloxymethyl groups, isocyanate compounds, azide compounds, and compounds having a double bond such as an alkenyl ether group. These compounds may be used as an additive or introduced into a polymer side chain as a pendant. Hydroxy-containing compounds may also be used as the crosslinker.

Of the foregoing crosslinkers, examples of suitable epoxy compounds include tris(2,3-epoxypropyl) isocyanurate, trimethylolmethane triglycidyl ether, trimethylolpropane triglycidyl ether, and triethylolethane triglycidyl ether. Examples of the melamine compound include hexamethylol melamine, hexamethoxymethyl melamine, hexamethylol melamine compounds having 1 to 6 methylol groups methoxymethylated and mixtures thereof, hexamethoxyethyl melamine, hexaacyloxymethyl melamine, hexamethylol melamine compounds having 1 to 6 methylol groups acyloxymethylated and mixtures thereof. Examples of the guanamine compound include tetramethylol guanamine, tetramethoxymethyl guanamine, tetramethylol guanamine compounds having 1 to 4 methylol groups methoxymethylated and mixtures thereof, tetramethoxyethyl guanamine, tetraacyloxyguanamine, tetramethylol guanamine compounds having 1 to 4 methylol groups acyloxymethylated and mixtures thereof. Examples of the glycoluril compound include tetramethylol glycoluril, tetramethoxyglycoluril, tetramethoxymethyl glycoluril, tetramethylol glycoluril compounds having 1 to 4 methylol groups methoxymethylated and mixtures thereof tetramethylol glycoluril compounds having 1 to 4 methylol groups acyloxymethylated and mixtures thereof. Examples of the urea compound include tetramethylol urea, tetramethoxymethyl urea, tetramethylol urea compounds having 1 to 4 methylol groups methoxymethylated and mixtures thereof, and tetramethoxyethyl urea.

Suitable isocyanate compounds include tolylene diisocyanate, diphenylmethane diisocyanate, hexamethylene diisocyanate and cyclohexane diisocyanate. Suitable azide compounds include 1,1′-biphenyl-4,4′-bisazide, 4,4′-methylidenebisazide, and 4,4′-oxybisazide. Examples of the alkenyl ether group-containing compound include ethylene glycol divinyl ether, triethylene glycol divinyl ether, 1,2-propanediol divinyl ether, 1,4-butanediol divinyl ether, tetramethylene glycol divinyl ether, neopentyl glycol divinyl ether, trimethylol propane trivinyl ether, hexanediol divinyl ether, 1,4-cyclohexanediol divinyl ether, pentaerythritol trivinyl ether, pentaerythritol tetravinyl ether, sorbitol tetravinyl ether, sorbitol pentavinyl ether, and trimethylol propane trivinyl ether.

In the negative resist composition, the crosslinker is preferably added in an amount of 0.1 to 50 parts, more preferably 1 to 40 parts by weight per 100 parts by weight of the base polymer.

In the resist composition of the invention, a quencher may be blended. The quencher is typically selected from conventional basic compounds. Conventional basic compounds include primary, secondary, and tertiary aliphatic amines, mixed amines, aromatic amines, heterocyclic amines, nitrogen-containing compounds with carboxyl group, nitrogen-containing compounds with sulfonyl group, nitrogen-containing compounds with hydroxyl group, nitrogen-containing compounds with hydroxyphenyl group, alcoholic nitrogen-containing compounds, amide derivatives, imide derivatives, and carbamate derivatives. Also included are primary, secondary, and tertiary amine compounds, specifically amine compounds having a hydroxyl, ether, ester, lactone ring, cyano, or sulfonic acid ester group as described in JP-A 2008-111103, paragraphs [0146]-[0164], and compounds having a carbamate group as described in JP 3790649. Addition of a basic compound may be effective for further suppressing the diffusion rate of acid in the resist film or correcting the pattern profile.

Onium salts such as sulfonium salts, iodonium salts and ammonium salts of sulfonic acids which are not fluorinated at α-position and similar onium salts of carboxylic acid may also be used as the quencher. While an α-fluorinated sulfonic acid, imide acid, and methide acid are necessary to deprotect the acid labile group of carboxylic acid ester, an α-non-fluorinated sulfonic acid or a carboxylic acid is released by salt exchange with an α-non-fluorinated onium salt. An α-non-fluorinated sulfonic acid and a carboxylic acid function as a quencher because they do not induce deprotection reaction.

Also a carboxylic acid onium salt having the formula (4) is useful as the quencher. R⁴⁰¹—CO₂ ⁻M_(A) ⁺  (4)

In formula (4), R⁴⁰¹ is a C₁-C₄₀ straight, branched or cyclic monovalent hydrocarbon group which may contain a heteroatom. M_(A) ⁺ is an onium ion such as a sulfonium, iodonium or ammonium ion.

Preferably the anion moiety in the carboxylic acid onium salt has the formula (5).

In formula (5), R⁴⁰² and R⁴⁰³ are each independently hydrogen, fluorine or trifluoromethyl. R⁴⁰⁴ is hydrogen, hydroxyl, a C₁-C₃₅ straight, branched or cyclic monovalent hydrocarbon group which may contain a heteroatom, or a substituted or unsubstituted C₁-C₃₀ aryl group.

Also useful are quenchers of polymer type as described in U.S. Pat. No. 7,598,016 (JP-A 2008-239918). The polymeric quencher segregates at the resist surface after coating and thus enhances the rectangularity of resist pattern. When a protective film is applied as is often the case in the immersion lithography, the polymeric quencher is also effective for preventing a film thickness loss of resist pattern or rounding of pattern top.

The quencher is preferably added in an amount of 0 to 5 parts, more preferably 0 to 4 parts by weight per 100 parts by weight of the base polymer.

To the resist composition, a polymeric additive (or water repellency improver) may also be added for improving the water repellency on surface of a resist film as spin coated. The water repellency improver may be used in the topcoatless immersion lithography. Suitable water repellency improvers include polymers having a fluoroalkyl group and polymers having a specific structure with a 1,1,1,3,33-hexafluoro-2-propanol residue and are described in JP-A 2007-297590 and JP-A 2008-111103, for example. The water repellency improver to be added to the resist composition should be soluble in the organic solvent as the developer. The water repellency improver of specific structure with a 1,1,1,3,3,3-hexafluoro-2-propanol residue is well soluble in the developer. A polymer having an amino group or amine salt copolymerized as recurring units may serve as the water repellent additive and is effective for preventing evaporation of acid during PEB, thus preventing any hole pattern opening failure after development. An appropriate amount of the water repellency improver is 0 to 20 parts, preferably 0.5 to 10 parts by weight per 100 parts by weight of the base polymer.

Also, an acetylene alcohol may be blended in the resist composition. Suitable acetylene alcohols are described in JP-A 2008-122932, paragraphs [0179]-[0182]. An appropriate amount of the acetylene alcohol blended is 0 to 5 parts by weight per 100 parts by weight of the base polymer.

Process

The resist composition is used in the fabrication of various integrated circuits. Pattern formation using the resist composition may be performed by well-known lithography processes. The process generally involves coating, prebaking, exposure, optional PEB, and development. If necessary, any additional steps may be added.

For example, the positive resist composition is first applied onto a substrate on which an integrated circuit is to be formed (e.g., Si, SiO₂, SiN, SiON, TiN, WSi, BPSG, SOG, or organic antireflective coating) or a substrate on which a mask circuit is to be formed (e.g., Cr, CrO, CrON, MoSi₂, or SiO₂) by a suitable coating technique such as spin coating, roll coating, flow coating, dipping, spraying or doctor coating. The coating is prebaked on a hotplate at a temperature of 60 to 150° C. for 10 seconds to 30 minutes, preferably at 80 to 120° C. for 30 seconds to 20 minutes. The resulting resist film is generally 0.01 to 2.0 μm thick.

The resist film is then exposed to a desired pattern of high-energy radiation such as UV, deep-UV, EB, EUV, x-ray, soft x-ray, excimer laser light, γ-ray or synchrotron radiation, directly or through a mask. The exposure dose is preferably about 1 to 200 mJ/cm², more preferably about 10 to 100 mJ/cm², or about 0.1 to 100 μC/cm², more preferably about 0.5 to 50 μC/cm². The resist film is further baked (PEB) on a hotplate at 60 to 150° C. for 10 seconds to 30 minutes, preferably at 80 to 120° C. for 30 seconds to 20 minutes.

Thereafter the resist film is developed with a developer in the form of an aqueous base solution for 3 seconds to 3 minutes, preferably 5 seconds to 2 minutes by conventional techniques such as dip, puddle and spray techniques. A typical developer is a 0.1 to 10 wt %, preferably 2 to 5 wt % aqueous solution of tetramethylammonium hydroxide (TMAH), tetraethylammonium hydroxide (TEAH), tetrapropylammonium hydroxide (TPAH), or tetrabutylammonium hydroxide (TBAH). The resist film in the exposed area is dissolved in the developer whereas the resist film in the unexposed area is not dissolved. In this way, the desired positive pattern is formed on the substrate. Inversely in the case of negative resist, the exposed area of resist film is insolubilized and the unexposed area is dissolved in the developer. It is appreciated that the resist composition of the invention is best suited for micro-patterning using such high-energy radiation as KrF and ArF excimer laser, EB, EUV, x-ray, soft x-ray, γ-ray and synchrotron radiation.

In an alternative embodiment, a negative pattern may be formed via organic solvent development using a positive resist composition comprising a base polymer having an acid labile group. The developer used herein is preferably selected from among 2-octanone, 2-nonanone, 2-heptanone, 3-heptanone, 4-heptanone, 2-hexanone, 3-hexanone, diisobutyl ketone, methylcyclohexanone, acetophenone, methylacetophenone, propyl acetate, butyl acetate, isobutyl acetate, pentyl acetate, butenyl acetate, isopentyl acetate, propyl formate, butyl formate, isobutyl formate, pentyl formate, isopentyl formate, methyl valerate, methyl pentenoate, methyl crotonate, ethyl crotonate, methyl propionate, ethyl propionate, ethyl 3-ethoxypropionate, methyl lactate, ethyl lactate, propyl lactate, butyl lactate, isobutyl lactate, pentyl lactate, isopentyl lactate, methyl 2-hydroxyisobutyrate, ethyl 2-hydroxyisobutyrate, methyl benzoate, ethyl benzoate, phenyl acetate, benzyl acetate, methyl phenylacetate, benzyl formate, phenylethyl formate, methyl 3-phenylpropionate, benzyl propionate, ethyl phenylacetate, and 2-phenylethyl acetate, and mixtures thereof.

At the end of development, the resist film is rinsed. As the rinsing liquid, a solvent which is miscible with the developer and does not dissolve the resist film is preferred. Suitable solvents include alcohols of 3 to 10 carbon atoms, ether compounds of 8 to 12 carbon atoms, alkanes, alkenes, and alkynes of 6 to 12 carbon atoms, and aromatic solvents. Specifically, suitable alcohols of 3 to 10 carbon atoms include n-propyl alcohol, isopropyl alcohol, 1-butyl alcohol, 2-butyl alcohol, isobutyl alcohol, t-butyl alcohol, 1-pentanol, 2-pentanol, 3-pentanol, t-pentyl alcohol, neopentyl alcohol, 2-methyl-1-butanol, 3-methyl-1-butanol, 3-methyl-3-pentanol, cyclopentanol, 1-hexanol, 2-hexanol, 3-hexanol, 2,3-dimethyl-2-butanol, 3,3-dimethyl-1-butanol, 3,3-dimethyl-2-butanol, 2-ethyl-1-butanol, 2-methyl-1-pentanol, 2-methyl-2-pentanol, 2-methyl-3-pentanol, 3-methyl-1-pentanol, 3-methyl-2-pentanol, 3-methyl-3-pentanol, 4-methyl-1-pentanol, 4-methyl-2-pentanol, 4-methyl-3-pentanol, cyclohexanol, and 1-octanol. Suitable ether compounds of 8 to 12 carbon atoms include di-n-butyl ether, diisobutyl ether, di-s-butyl ether, di-n-pentyl ether, diisopentyl ether, di-s-pentyl ether, di-t-pentyl ether, and di-n-hexyl ether. Suitable alkanes of 6 to 12 carbon atoms include hexane, heptane, octane, nonane, decane, undecane, dodecane, methylcyclopentane, dimethylcyclopentane, cyclohexane, methylcyclohexane, dimethylcyclohexane, cycloheptane, cyclooctane, and cyclononane. Suitable alkenes of 6 to 12 carbon atoms include hexene, heptene, octene, cyclohexene, methylcyclohexene, dimethylcyclohexene, cycloheptene, and cyclooctene. Suitable alkynes of 6 to 12 carbon atoms include hexyne, heptyne, and octyne. Suitable aromatic solvents include toluene, xylene, ethylbenzene, isopropylbenzene, t-butylbenzene and mesitylene. The solvents may be used alone or in admixture.

Rinsing is effective for minimizing the risks of resist pattern collapse and defect formation. However, rinsing is not essential. If rinsing is omitted, the amount of solvent used may be reduced.

A hole or trench pattern after development may be shrunk by the thermal flow, RELACS® or DSA process. A hole pattern is shrunk by coating a shrink agent thereto, and baking such that the shrink agent may undergo crosslinking at the resist surface as a result of the acid catalyst diffusing from the resist layer during bake, and the shrink agent may attach to the sidewall of the hole pattern. The bake is preferably at a temperature of 70 to 180° C., more preferably 80 to 170° C., for a time of 10 to 300 seconds. The extra shrink agent is stripped and the hole pattern is shrunk.

EXAMPLE

Examples of the invention are given below by way of illustration and not by way of limitation. The abbreviation “pbw” is parts by weight.

PAG Monomers 1 to 7 and Comparative PAG Monomer 1 used in Synthesis Examples are identified below.

Synthesis Example 1

Synthesis of Polymer 1

A 2-L flask was charged with 8.4 g of 1-methyl-1-cyclopentyl methacrylate, 3.6 g of 4-hydroxyphenyl methacrylate, 4.5 g of 3-oxo-2,7-dioxatricyclo[4.2.1.0^(4,8)]nonan-9-yl methacrylate, 8.1 g of PAG Monomer 1, and 40 g of THF as solvent. The reactor was cooled at −70° C. in nitrogen atmosphere, after which vacuum pumping and nitrogen blow were repeated three times. The reactor was warmed up to room temperature, whereupon 1.2 g of azobisisobutyronitrile (AIBN) as polymerization initiator was added. The reactor was heated at 60° C., whereupon reaction ran for 15 hours. The reaction solution was poured to into 1 L of isopropyl alcohol for precipitation. The white solid precipitate was collected by filtration and dried in vacuum at 60° C., yielding Polymer 1 in white solid form. Polymer 1 was analyzed for composition by ¹³C- and ¹H-NMR and for Mw and Mw/Mn by GPC.

Synthesis Example 2

Synthesis of Polymer 2

Polymer 2 was obtained in white solid form by the same procedure as in Synthesis Example 1 aside from using 10.3 g of PAG Monomer 2 instead of PAG Monomer 1. Polymer 2 was analyzed for composition by ¹³C- and ¹H-NMR and for Mw and Mw/Mn by GPC.

Synthesis Example 3

Synthesis of Polymer 3

Polymer 3 was obtained in white solid form by the same procedure as in Synthesis Example 1 aside from using 10.3 g of PAG Monomer 3 instead of PAG Monomer 1. Polymer 3 was analyzed for composition by ¹³C- and ¹H-NMR and for Mw and Mw/Mn by GPC.

Synthesis Example 4

Synthesis of Polymer 4

Polymer 4 was obtained in white solid form by the same procedure as in Synthesis Example 1 aside from using 9.3 g of PAG Monomer 4 instead of PAG Monomer 1. Polymer 4 was analyzed for composition by ¹³C- and ¹H-NMR and for Mw and Mw/Mn by GPC.

Synthesis Example 5

Synthesis of Polymer 5

A 2-L flask was charged with 8.4 g of 1-methyl-1-cyclopentyl methacrylate, 4.8 g of 4-hydroxystyrene, 9.1 g of PAG Monomer 5, and 40 g of THF as solvent. The reactor was cooled at −70° C. in nitrogen atmosphere, after which vacuum pumping and nitrogen blow were repeated three times. The reactor was warmed up to room temperature, whereupon 1.2 g of AIBN as polymerization initiator was added. The reactor was heated at 60° C., whereupon reaction ran for 15 hours. The reaction solution was poured into 1 L of isopropyl alcohol for precipitation. The white solid precipitate was collected by filtration and dried in vacuum at 60° C., yielding Polymer 5 in white solid form. Polymer 5 was analyzed for composition by ¹³C- and ¹H-NMR and for Mw and Mw/Mn by GPC.

Synthesis Example 6

Synthesis of Polymer 6

Polymer 6 was obtained in white solid form by the same procedure as in Synthesis Example 5 aside from using 7.1 g of PAG Monomer 6 instead of PAG Monomer 5. Polymer 6 was analyzed for composition by ¹³C- and ¹H-NMR and for Mw and Mw/Mn by GPC.

Synthesis Example 7

Synthesis of Polymer 7

Polymer 7 was obtained in white solid form by the same procedure as in Synthesis Example 5 aside from using 9.2 g of PAG Monomer 7 instead of PAG Monomer 5. Polymer 7 was analyzed for composition by ¹³C- and ¹H-NMR and for Mw and Mw/Mn by GPC.

Synthesis Example 8

Synthesis of Polymer 8

Polymer 8 was obtained in white solid form by the same procedure as in Synthesis Example 7 aside from using 13.5 g of 4-amyloxy-3-fluorostyrene instead of 1-methyl-1-cyclopentyl methacaylate and using 3.0 g of 4-hydroxystyrene. Polymer 8 was analyzed for composition by ¹³C- and ¹H-NMR and for Mw and Mw/Mn by GPC.

Comparative Synthesis Example 1

Synthesis of Comparative Polymer 1

Comparative Polymer 1 was obtained in white solid form by the same procedure as in Synthesis Example 1 aside from using 7.6 g of Comparative PAG Monomer 1 instead of PAG Monomer 1. The polymer was analyzed for composition by ¹³C- and ¹H-NMR and for Mw and Mw/Mn by GPC.

Examples 1 to 11 and Comparative Example 1

1) Preparation of Resist Composition

Resist compositions were prepared by dissolving components in a solvent in accordance with the recipe shown in Table 1, and filtering through a filter having a pore size of 0.2 μm. The solvent contained 100 ppm of surfactant FC-4430 (3M). The components in Table 1 are as identified below.

Organic Solvents:

PGMEA (propylene glycol monomethyl ether acetate)

CyH (cyclohexanone)

PGME (propylene glycol monomethyl ether)

DAA (diacetone alcohol)

Acid Generators: PAG 1 to PAG 3 of the Following Structural Formulae

Quenchers: Quenchers 1 and 2 of the Following Structural Formulae

2) EUV Lithography Test

Each of the resist compositions of Examples 1 to 11 and Comparative Example 1 was spin coated on a silicon substrate having a 20-nm coating of silicon-containing spin-on hard mask SHB-A940 (silicon content 43 wt %, Shin-Etsu Chemical Co., Ltd.) and prebaked on a hotplate at 105° C. for 60 seconds to form a resist film of 60 nm thick. Using an EUV scanner NXE3300 (ASML, NA 0.33, σ0.9/0.6, quadrupole illumination), the resist film was exposed to EUV through a mask bearing a hole pattern at a pitch 46 in (on-wafer size) and +20% bias. The resist film was baked (PEB) on a hotplate at the temperature shown in Table 1 and developed in a 2.38 wt % TMAH aqueous solution for 30 seconds to form a hole pattern having a size of 23 nm.

The resist pattern was evaluated. The exposure dose that provides a hole pattern having a size of 23 nm is reported as sensitivity. The size of 50 holes was measured under CD-SEM (CG-5000, Hitachi High-Technologies Corp.), from which a size variation (3σ) was computed and reported as CDU.

The resist composition is shown in Table 1 together with the sensitivity and CDU of EUV lithography.

TABLE 1 Acid PEB Polymer generator Base Organic solvent temp. Sensitivity CDU (pbw) (pbw) (pbw) (pbw) (° C.) (mJ/cm²) (nm) Example 1 Polymer 1 — Quencher 1 PGMEA (400) 100 28 2.1 (100) (3.00) CyH (2,000) PGME (100) Example 2 Polymer 2 — Quencher 1 PGMEA (400) 100 26 2.4 (100) (3.00) CyH (2,000) PGME (100) Example 3 Polymer 3 — Quencher 1 PGMEA (2,000) 100 24 2.2 (100) (3.00) DAA (500) Example 4 Polymer 4 — Quencher 1 PGMEA (2,000) 100 23 2.2 (100) (3.00) DAA (500) Example 5 Polymer 5 — Quencher 1 PGMEA (2,000) 100 21 2.2 (100) (3.00) DAA (500) Example 6 Polymer 6 — Quencher 1 PGMEA (2,000) 100 20 2.3 (100) (3.00) DAA (500) Example 7 Polymer 7 — Quencher 1 PGMEA (2,000) 100 20 2.4 (100) (3.00) DAA (500) Example 8 Polymer 8 — Quencher 1 PGMEA (2,000) 100 26 2.0 (100) (3.00) DAA (500) Example 9 Polymer 1 PAG 1 Quencher 2 PGMEA (2,000) 100 17 2.7 (100) (7.0) (3.00) DAA (500) Example 10 Polymer 1 PAG 2 Quencher 2 PGMEA (2,000) 100 16 2.7 (100) (10.0) (3.00) DAA (500) Example 11 Polymer 1 PAG 3 Quencher 2 PGMEA (2,000) 100 15 2.6 (100) (10.0) (3.00) DAA (500) Comparative Comparative — Quencher 1 PGMEA (400) 100 36 4.0 Example 1 Polymer 1 (3.00) CyH (2,000) (100) PGME (100)

It is demonstrated in Table 1 that resist compositions comprising a polymer comprising recurring units of formula (a1) or (a2) within the scope of the invention offer a high sensitivity and improved CDU.

Japanese Patent Application No. 2017-100594 is incorporated herein by reference.

Although some preferred embodiments have been described, many modifications and variations may be made thereto in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described without departing from the scope of the appended claims. 

The invention claimed is:
 1. A resist composition comprising a polymer comprising recurring units having the formula (a1-1) or (a2-2):

wherein R^(A) is hydrogen or methyl, X¹ is a single bond or ester group Rf¹ to Rf⁴ are each independently hydrogen, fluorine or trifluoromethyl, at least one of Rf¹ to Rf⁴ is fluorine or trifluoromethyl, Rf¹ and Rf² may bond together to form a carbonyl group, R¹ to R⁵ are each independently a C₁-C₁₂ straight, branched or cyclic alkyl group, C₂-C₁₂ straight, branched or cyclic alkenyl group, C₂-C₁₂ straight, branched or cyclic alkynyl group, C₆-C₂₀ aryl group, C₇-C₁₂ aralkyl group, or C₇-C₁₂ aryloxyalkyl group, in which at least one hydrogen may be substituted by hydroxyl, carboxyl, halogen, oxo, cyano, amide, nitro, sultone, sulfone or sulfonium salt-containing moiety, and in which any methylene moiety may be substituted by an ether, ester, carbonyl, carbonate or sulfonate moiety, R¹ and R² may bond together to form a ring with the sulfur atom to which they are attached, R⁶ is a C¹-C⁴ straight, branched or cyclic alkyl group, halogen atom exclusive of iodine, hydroxyl group, C₁-C₄ straight, branched or cyclic alkoxy group, or C₂-C₅ straight, branched or cyclic alkoxycarbonyl group, m is an integer of 1 to 4, and n is an integer of 0 to
 3. 2. The resist composition of claim 1, further comprising an organic solvent.
 3. The resist composition of claim 1, wherein the polymer further comprises recurring units having the formula (b1) or (b2):

wherein R^(A) is independently hydrogen or methyl, Y¹ is a single bond, phenylene group, naphthylene group, or a C₁-C₁₂ linking group containing an ester moiety and/or lactone ring, Y² is a single bond or ester group, R¹¹ and R¹² are each independently an acid labile group, R¹³ is halogen, trifluoromethyl, cyano, C₁-C₆ straight, branched or cyclic alkyl or alkoxy group, or C₂-C₇ straight, branched or cyclic acyl, acyloxy or alkoxycarbonyl group, R¹⁴ is a single bond or C₁-C₆ straight or branched alkylene group in which at least one carbon atom may be substituted by an ether or ester moiety, p is 1 or 2, and q is an integer of 0 to
 4. 4. The resist composition of claim 3, further comprising a dissolution inhibitor, the resist composition being a chemically amplified positive tone resist composition.
 5. The resist composition of claim 1 wherein the polymer is free of an acid labile group.
 6. The resist composition of claim 5, further comprising a crosslinker, the resist composition being a chemically amplified negative tone resist composition.
 7. The resist composition of claim 1, further comprising a surfactant.
 8. A process for forming a pattern comprising the steps of applying the resist composition of claim 1 onto a substrate, baking to form a resist film, exposing the resist film to high-energy radiation, and developing the exposed film in a developer.
 9. The process of claim 8 wherein the high-energy radiation is ArF excimer laser radiation of wavelength 193 nm or KrF excimer laser radiation of wavelength 248 nm.
 10. The process of claim 8 wherein the high-energy radiation is electron beam or extreme ultraviolet radiation of wavelength 3 to 15 nm.
 11. The resist composition of claim 1 wherein the polymer further comprises recurring units (c) having a phenolic hydroxyl group as an adhesive group.
 12. The resist composition of claim 11 wherein the recurring units (c) are selected from the group consisting of the following formulae: 